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Subaru Tribeca Engine Service Guide

1. The document provides information on servicing an automobile engine, including descriptions of engine parts, assembly diagrams, diagnostic procedures, and specifications. It emphasizes cleanliness and protecting machined surfaces during assembly and repair. 2. Diagnostic procedures described include locating oil leaks through visual inspection and using powder or dye, and performing compression pressure and cylinder leakage tests to diagnose engine issues. 3. Specifications provided include engine details, fastener tightening torques, and performance curves. Careful inspection and following specifications are important for properly servicing the engine.

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0% found this document useful (0 votes)
43 views20 pages

Subaru Tribeca Engine Service Guide

1. The document provides information on servicing an automobile engine, including descriptions of engine parts, assembly diagrams, diagnostic procedures, and specifications. It emphasizes cleanliness and protecting machined surfaces during assembly and repair. 2. Diagnostic procedures described include locating oil leaks through visual inspection and using powder or dye, and performing compression pressure and cylinder leakage tests to diagnose engine issues. 3. Specifications provided include engine details, fastener tightening torques, and performance curves. Careful inspection and following specifications are important for properly servicing the engine.

Uploaded by

manual
Copyright
© All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd

1113-01 01-3

1. DESCRIPTION AND OPERATION


1) Cleanliness and Care
An automobile engine is a combination of many machined, honed, polished and lapped surfaces with
tolerances that are measured in the ten-thousanths of an inch.
When any internal engine parts are serviced, care and cleanliness are important.
A liberal coating of enigne oil should be applied to friction areas during assembly, to protect and lubricate
the surfaces on initial operation. Proper cleaning and protection of machined surfaces and friction areas
is part of the repair procedure.
This is considered standard shop practice even if not specifically stated.
Whenever valve train components are removed for service, they should be kept in order. They should be
installed in the same locations, and with the same mating surfaces, as when they were removed.
Battery cables should be disconnected before any major work is performed on the engine. Failure to
disconnect cables may result in damage to wire harness or other electrical parts.
01-4

2) On-engine Service

- Disconnect the negative battery cable before removing or installing any electrical unit, or when a
tool or equipment could easily come in contact with exposed electrical terminals.
Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition
must also be in LOCK unless otherwise noted.

- Any time the air cleaner is removed, the intake opening should be covered. This will protect
against accidental entrance of foreign material, which could follow the intake passage into the
cylinder and cause extensive damage when the engine is started.
1113-01 01-5

2. G23D ENGINE ASSEMBLY


Front View

Rear View
01-6

LH Side View

RH Side View
1113-01 01-7

3. G23D ENGINE STRUCTURE


Front View

Side View
01-8

▶ Front View

NO. FUNCTION NO. FUNCTION


1 HFM Sensor 12 Intake Manifold
2 Intake Air Duct 13 Cylinder Head
3 Cylinder Head Cover 14 Exhaust Manifold
4 Ignition Coi 15 Dipstick Guide Tube and Gauge
5 Spark Plug Connector 16 Connecting Rod
6 Fuel Distributor 17 Crankshaft
7 Injector 18 Engine Mounting Bracket
8 Exhaust Camshaft 19 Starter
9 Intake Camshaft 20 Crankcase
10 Valve Tappet 21 Oil Pump Sprocket
11 Intake Valve 22 Oil Pan

▶ Side View

NO. FUNCTION NO. FUNCTION


23 Camshaft Adjuster 29 Oil Pump Drive Chain
24 Oil Filler Cap 30 Oil Strainer
25 Engine Hanger Bracket 31 Oil Pump
26 Cooling Fan and Viscous Clutch 32 Ring Gear and Flywheel of Drive Plate
27 Oil Filter 33 Piston
28 Timing Chain
1113-01 01-9

4. DIAGNOSTIC INFORMATION AND PROCEDURE


1) Oil Leak Diagnosis
Most fluid oil leaks are easily located and repaired by visually finding the leak and replacing or repairing
the necessary parts. On some occasions a fluid leak may be difficult to locate or repair. The following
procedures may help you in locating and repairing most leaks.

▶ Finding the Leak


- Identify the fluid. Determine whether it is engine oil, automatic transmission fluid, power steering
fluid, etc.
- Identify where the fluid is leaking from.
· After running the vehicle at normal operating temperature, park the vehicle over a large sheet
of paper.
· Wait a few minutes.
· You should be able to find the approximate location of the leak by the drippings on the paper.

- Visually check around the suspected component.


Check around all the gasket mating surfaces for leaks. A mirror is useful for finding leaks in
areas that are hard to reach.
- If the leak still cannot be found, it may be necessary to clean the suspected area with a
degreaser, steam or spray solvent.
· Clean the area well.
· Dry the area.
· Operate the vehicle for several miles at normal operating temperature and varying speeds.
After operating the vehicle, visually check the suspected component.
· If you still cannot locate the leak, try using the powder or black light and dye method.
·

▶ Powder Method
- Clean the suspected area.
- Apply an aerosol-type powder (such as foot powder) to the suspected area.
- Operate the vehicle under normal operating conditoins.
- Visually inspect the suspected component. You should be able to trace the leak path over the
white powder surface to the source.
01-10

▶ Black Light and Dye Method


A dye and light kit is available for finding leaks, Refer to the manufacturer's directions when using the kit.

- Pour the specified amount of dye into the engine oil fill tube.
- Operate the vehicle normal operating conditions as directed in the kit.
- Direct the light toward the suspected area. The dyed fluid will appear as a yellow path leading to
the source.

▶ Repairing the Leak


Once the origin of the leak has been pinpointed and traced back to its source, the cause of the leak must
be determined in order for it to be repaired properly.
If a gasket is replaced, but the sealing flange is bent, the new gasket will not repair the leak. The bent
flange must be repaired also. Before attempting to repair a leak, check for the following conditions and
correct them as they may cause a leak.

▶ Gaskets
- The fluid level/pressure is too high.
- The crankcase ventilation system is malfunctioning.
- The seal bore is damaged (scratched, burred or nicked).
- The seal is damaged or worn.
- Improper installation is evident.
- There are cracks in the components.
- The shaft surface is scratched, nicked or damaged.
- A loose or worn bearing is causing excess seal wear.
1113-01 01-11

2) Compression Pressure Test

▶ Standard Service Data

- A9912 0012B (001 589 76 21 00) Compression Pressure Tester

▶ Measuring Procedure
- Warm the engine up to normal operating temperature.
- Remove the spark plugs using the spark plug wrench.
- Place the diagram sheet to compression pressure tester A9912 0012B (001 589 76 21 00).
Connect the adaptor to compression pressure tester A9912 0012B (001 589 76 21 00) and
- install it into the spark plug hole.
Crank the engine approx. eight revolutions by using the start motor.
- Compare the measurements of compression pressure tester A9912 0012B (001 589 76 21 00)
- with the specifications.
Measure the compression pressure of the other cylinders in the same way.
- If measured value is not within the specifications, perform the cylinder pressure leakage test.
-

- Discharge the combustion residues in the cylinders before testing the compression pressure.
Apply the parking brake before cranking the engine.
-
01-12

3) Cylinder Pressure LeakageTest

▶ Permissible Pressure Leakage

At Whole Engine Max. 25 %


At Valve and Cylinder Head Gasket Max. 10 %
At Piston and Piston Ring Max. 20 %

▶ Cylinder Number

OT (TDC) 1, 4
UT (BDC 180 °) 2, 3

▶ Cylinder Number

Cylinder Pressure Bosch, EFAW210A


Leakage Tester Sun, CLT 228
1113-01 01-13

▶ Leakage Test
- Warm the engine up to normal operating temperature.
- Disconnect the negative battery cable.
- Remove the spark plugs.
- Check the coolant level by opening the coolant reservoir cap and replenish if insufficient.
- Open the engine oil filler cap.
- Connect the tester to air pressure line and adjust the scale of tester.
- Install the connecting hose to spark plug hole.
- Position the piston of No.1 cylinder at TDC by rotating the crankshaft.
- Connect the connecting hose to tester and measure the leakage volume after blowing up
5 bar of compressed air.

- Measure the leakage volume in the completely opening condition of throttle valve by pulling the
acceleration cable.

- Perform the pressure test according to the firing order.

- Firing Order: 1 - 3 - 4 - 2

- Compare the leakage pressure with the specifications.


01-14

5. GENERAL DIAGNOSIS
1113-01 01-15

▶ General Diagnosis (Cont'd)


01-16

▶ General Diagnosis (Cont'd)


1113-01 01-17

▶ General Diagnosis (Cont'd)


01-18

▶ General Diagnosis (Cont'd)


1113-01 01-19

6. SPECIFICATIONS
1) Engine Specifications

MSE : Engine Control Module


3.53D : 4 Cylinder Version
01-20

2) Fastener Tightening Specifications


1113-01 01-21

▶ Fastener Tightening Specifications (Cont'd)


01-22

2) Performance Curve

Common questions

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The cylinder pressure leakage test involves warming the engine to normal operating temperature, disconnecting the battery, removing spark plugs, and connecting a leakage tester to the engine to measure air pressure loss in each cylinder . The purpose is to identify the source and extent of leaks within the engine cylinder which impact performance. Permissible pressure values include a maximum of 25% for the whole engine, 10% at valve and cylinder head gaskets, and 20% at piston and piston rings . Values exceeding these limits suggest issues such as damaged gaskets or piston rings, potentially causing reduced engine efficiency or power.

To conduct a compression pressure test, warm the engine to normal operating temperature, then remove the spark plugs using a spark plug wrench. Connect a compression pressure tester to the spark plug hole, crank the engine approximately eight times, and compare the measurements to specifications . This test is important as it helps diagnose issues related to compression leaks, which can indicate worn components, such as piston rings or valves, potentially leading to reduced engine performance or failure .

To identify fluid leaks, visually check around the suspected component, especially gasket mating surfaces. For hard-to-reach areas, a mirror can be used . More precise methods include cleaning the area with a degreaser or solvent, or applying an aerosol powder like foot powder to trace the leak path . The powder method allows visual confirmation of leak paths but requires undisturbed conditions. The black light and dye method involves pouring dye into the fluid and using a black light to trace the leak path by observing a yellow glow . This method is highly accurate but requires specific equipment. Each method has its advantages: visual checks are straightforward but less precise, powder is nondestructive but depends on ideal conditions, and dye requires equipment but offers accuracy.

Cleanliness and order are crucial when servicing internal engine parts because they prevent contamination and ensure proper function and longevity of the engine components. During service, it is important to apply a liberal coating of engine oil to friction areas to protect and lubricate them upon initial operation . Keeping valve train components in order ensures they are reinstalled in the same location and with the same mating surfaces, maintaining the original tolerance levels . This meticulous approach prevents wear, misalignment, and potential failures.

When performing on-engine service, it is crucial to disconnect the negative battery cable before removing or installing any electrical unit or when contact with exposed electrical terminals is possible. This precaution prevents personal injuries and damage to the vehicle’s electrical system . Additionally, the ignition should be in LOCK unless otherwise noted to further ensure safety . These measures are critical to avoid electrical shocks, fires, and potential damage to vehicle components.

Using specific tools such as a compression pressure tester or a cylinder pressure leakage tester is necessary because they provide precise measurements of engine condition that cannot be accurately assessed through visual inspection alone . These tools allow for detailed diagnosis of internal pressures in engine cylinders, identifying potential issues with components like pistons, rings, or valves . The accuracy of these measurements enables mechanics to make informed decisions about necessary repairs, ensuring more reliable and efficient engine performance.

Diagnosing oil leaks involves identifying the fluid type, locating the leak source, and checking gasket surfaces and components for breaches . If the leak is difficult to locate, the area may be cleaned with a degreaser and techniques like the powder or dye and black light method can be used to trace the leak path . Effective repair requires addressing root causes such as replacing damaged gaskets or seals and correcting flange or component damage to prevent recurrence . These comprehensive steps ensure the leak is accurately traced and properly repaired, restoring integrity and function to the engine.

Engine cleanliness during assembly is directly related to operational efficiency as clean components minimize the risk of contamination that can lead to wear and mechanical failures. Machined, honed, and polished surfaces in an engine require clean environments to prevent particle intrusion that can increase friction and degrade performance . Standard shop practices, such as cleaning and applying engine oil to friction areas, help maintain surface integrity and reduce initial wear at startup . These practices ensure tight tolerances are maintained, significantly contributing to the overall efficiency and lifespan of the engine.

Key causes of fluid leaks in a vehicle's engine include high fluid levels or pressure, malfunctioning crankcase ventilation systems, damaged seal bores, worn or improperly installed seals, component cracks, and scratched or damaged shaft surfaces . Maintenance practices such as regular inspection of seals and gaskets, ensuring proper installation of components, and maintaining correct fluid levels can mitigate these issues . Consistent monitoring and timely addressing of early signs of wear or damage prevent the potential for leaks developing into significant mechanical failures.

Disconnecting the battery during engine servicing is a critical safety measure that prevents accidental electrical discharges, which can cause injuries to the mechanic and damage sensitive electrical systems in the vehicle . Without this precaution, tools interacting with exposed electrical terminals can create sparks, leading to fires or shorts that can irreversibly damage components. This step effectively isolates the electrical system from tools or liquids encountered during servicing, providing a safer working environment and preventing costly repairs due to electrical mishaps.

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